What is soap and how is it made?

November 04, 2020

What is soap and how is it made?

The records of soap date back to 2800 BC where 

Babylonians made soap by mixing fats boiled with ashes. In our case our hand made line of Brawler Bars are made with all natural oils and ingredients mixed in with lye which is a caustic solution.

The process of making soap is when lye comes into contact with oils/fats, a chemical reaction takes place, then both of the substances change form. Once this reaction is complete there is no longer lye or fats, you are left with pure soap. This process is called saponification.

If soap is made properly, the lye is used up in the saponification process to turn oil into soap. There is no lye present in the finished product of our Brawler Bars. While all real soap must be made with lye, no lye remains in our finished products after saponification. When you read the ingredients on our packaging you will notice the listing of saponified oils in our soap bar. So essentially once our bars are curated you are left with a completely natural product for your skin.

I have the pleasure of being handling all of the manufacturing at Brawler Bar. In simple terms, I make the soap, which is not a job I take lightly. Some people are a little puzzled when they first follow us on Instagram and see that our bars are made by a fire fighter who swings kettle bells, but in honesty I love it. I love that Michelle (the marketing brains) and I get to create a product where all the profits go towards communities in need. 

Our Brawler Bar manufacturing takes place in a sterilised space through a few phases. First I start off mixing lye with my oils and fats and pour these into our Brawler Bar loaf moulds. I then cover and set our loaves in a dedicated unit which starts the saponification process. Depending on the bar and formula I am able to cut the loaves after 18-24 hours using one of my many fan dangle soap cutters and load them onto wooden trays to curate for 8-12 weeks before being packed and sold. It is a traditional process we follow but one we love as we know exactly what is going into each bar.

Every week as we gain more new wholesalers and online followers it brings a big grin to my face as I make more loaves of natural bars and get them ready for cutting. 

If you want to get your hands on one of our hand made bars check out our Mission Bar line here.

 

*Photo credit - a fresh batch of our Impurity Rocks and Sweet Summer Bars after our 12 week curation and ready to be packed.





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